Multiple control switch with sequential cam lobe actuators

ABSTRACT

A plurality of switch means disposed about a centrally disposed control member are sequentially actuated according to a programmed sequence as the control member is rotated about its axis. A plurality of cam lobes are attached to said control member, and engage spring-biased actuating means which are part of said switch means. A rotor which is responsive to said actuating means carries a boss which biases electrical contact means into selective engagement with cooperating electrical contacts.

United States Patent 72] Inventor Malcolm T. Lybrook Frankfort, Ind. [21] Appl. No. 13,494 [22] Filed Feb. 24, 1970 [45] Patented Jan. 11,1972 [73] Assignee P. R. Mallory & Co., Inc.

Indianapolis, Ind.

[54] MULTIPLE CONTROL SWITCH WITH SEQUENTIAL CAM LOBE ACTUATORS 6 Claims, 9 Drawing Figs.

[52] US. Cl ..200/l53 LB, 200/68 [51] Int. Cl H0lh 3/42, HOlh 21/42 [50] Field of Search 200/5 C, 153 LB, 153 L, 68, 63, 6 BA; 318/543 [56] References Cited UNITED STATES PATENTS 931,148 8/1909 Schairer 200/5 C 2,463,659 3/1949 Tiedeman ZOO/68 X 2,745,916 5/1956 Yingst 200/153 LB X 3,162,797 12/1964 Blanchard et al.. ZOO/153 LBX 3,190,977 6/1965 Harris ZOO/153 LB X FOREIGN PATENTS 925,340 5/1963 Great Britain 200/63 978,491 12/1964 Great Britain 200/68 Primary Examiner Robert K. Schaefer Assistant Examiner-Robert A. Vanderhye Attorneys-Richard H. Childress, Robert F. Meyer, Henry W.

Cummings and C. Carter Ells, Jr.

PATENTEU m1 1 1972 3634542 SHEET 3 UF 3 INVENTOR FIG 9 MALCOLM T LYBROOK ATTORNEY MULTIPLE CONTROL SWITCH WITH SEQUENTIAL CAM LOBE ACTUATORS This invention relates to control devices; more particularly it relates to a control device which provides a speed regulating means for a motor used to drive a device such as a blower.

In the operation of devices such as automobile heaters and air conditioners, blower means are used to regulate and direct the volume of air so as to control the amount of heat or cooling. Such blowers are driven by a suitable drive means such as a motor, with the motor being operated at various speeds in order to control the blower output.

in such applications, especially in those such as automobiles, the control systems used to regulate the amount of heat or cooling through blower control must, of necessity, be simple, compact and easy to produce.

The present invention is concerned with such a control means and has as one of its objects the provision of a control means which is simple, compact and easy to produce.

Another object of the invention is to provide a control means which permits higher operating currents to be safely used. I

Another object of the invention is to provide a control means utilizing a plurality of switch means which are switched to on-off positions according to a programmed sequence.

Still another object of the invention is to provide a control means utilizing a plurality of switch means which are switched to the on position in a cumulative sequence.

A further object of the invention is to provide a control means utilizing a plurality of switch means electrically connected in parallel, with electrical impedance means connected in series with all but one of the switch means.

Yet another object of the invention is to provide a control means having a plurality of switch means circumferentially disposed about the periphery of a control member which sequentially actuates the switch means.

These and other objects of the invention will become apparent from the following description and the accompanying drawings wherein:

FIG. 1 is an electrical schematic showing the control means of the present invention in cooperation with a blower motor;

FIG. 2 is a perspective view of the control means of the present invention;

FIG. 3 is a dead section in elevation taken along line 33 of FIG. 2;

FIG. 4 is a section taken along line 44 of FIG. 2 illustrating one of the switching elements of the control means;

FIG. 5 is a bottom view taken along line 55 of FIG. 3 showing the arrangement of the external leads of the terminals of the control means in cooperation with the base plate of the control means;

FIG. 6 is a section taken along line 6-6 of FIG. 3 illustrating the arrangement of the switching elements and cooperating parts;

FIG. 7 is a section taken along line 7-7 of FIG. 3 showing the cooperation between the movable contact rings and the stationary contact members;

FIG. 8 is a schematic similar to FIG. 1 showing another operating mode of the control means; and

FIG. 9 is a view of another embodiment of the control means in cooperation with an actuator means with portions thereof removed for the sake of clarity.

Generally speaking, the objects of the invention are accomplished by providing a control means comprising a plurality of electrical switch means electrically coupled between a power source and a load, and means selectively energizing the switch means in accordance with a programmed sequence.

Referring now to the drawings and more particularly to FIG. 1, one side of a power supply, such a battery 5, is electrically connected to one side of a load such as motor 4 which could operate a suitable blower for example. The other side of power supply 5 is connected to a common terminal or a ground terminal in the control means 10. Control means 10includes parallel switching means l2, 14, 16 and 18. The other side of control means 10 is coupled to the other side of the motor 4 through these switch means. Selectively coupled in series with the switch means l2, l4 and 16 are current limiting means of predetermined values such as resistors 6, 7 and 8 respectively. As will be apparent hereinafter, the mechanical movement in control means 10 results in the switch means l2, 14, 16 and 18 being selectively energized in a desired programmed sequence, which in the embodiment of FIG. 1 is a cumulative sequence. Switch 18 is directly coupled to motor 4, that is, there is no resistor thereby applying current directly to the motor. The switching means including resistors 6, 7 and 8 selectively varies the speed of motor 4 by varying the amount of voltage applied to it. The magnitude of the resistor may be varied as desired.

Referring now to FIGS. 2, 3 and 5, it can be seen that control means 10 includes a base member 20 which may be constructed of an insulative type material such as a phenolic resin. Located on the base member 20 and having portions projecting therethrough are electrical terminals 22, 24, 26 and 28. Terminals 22, 24, 26 and 28 lie in a transverse plane to that of the base member 20 with portions thereof projecting through the base member to provide stationary contact portions 22, 247, 26 and 28' respectively. A fifth terminal 30, which is'the ground or common side of the control means 10, lies substantially parallel to the surface of the baseplate 20. Ground terminal 30 includes a secondary or separate terminal plate 32. Terminal plate 32 includes ground stationary terminal contacts 23, 25, 27 and 29 located around its periphery to cooperate with the stationary terminals 22', 24', 26 and 28 respectively.

Ground terminal 30 and its terminal plate 32 are aligned and held in place with respect-to each other by suitable means such as a boss 34 on terminal 30, the boss 34 being receivably carried in a notch 36 on terminal plate 32. Ground terminal 30 and its terminal plate 32 are coupled together by suitable means such as, for example, by being mechanically staked and are retained to each other by way of a bushing 38 integrally formed out of the terminal plate 32. As will be hereinafter described, bushing 38 also provides a bearing surface for a mechanical actuator. The ground terminal 30 and its cooperating terminal plate 32 are substantially held in proper alignment with respect to the baseplate 20 by way of the contacts 23, 25, 27 and 29 projecting through the baseplate 20. Locating means are also provided to further hold ground terminal 30 in a rigid position with respect to baseplate 20. Such locating means includes bosses 44 which extend from cover plate 46 through aperture 40 of ground terminal 30 and aperture 42 of base member 20, the bosses being heat staked over base member 20. Cover plate 46 acts as an insulative cover for terminals 22, 24, 26, 28 and 30. Cover 46 also includes stop means such as lugs 50, 52, 54 and 56. These lugs are positioned in a proper location away from the stationary terminals and stationary ground contacts to thereby provide a stop or resting pad for the movable contacts in a manner hereinafter to be described.

Bushing 38 carries a control member 58. Control member 58 includes a hub portion 60, flange 63 having cam lobes 100, and shaft means 72. Hub portion 60 is receivably carried in bushing 38 and in mounting'plate through a neck portion having a bearing surface 62. Mounting plate 70 is mechanically coupled to a cover plate 68 by way of a bushing 66 which is staked or mechanically rolled over to secure the cover plate 68 to the mounting plate 70. It can be seen in FIG. 2 that the cover plate 68 has a plurality of gripping means such as tabs 64 for mechanically securing the cover plate 68 to the base plate 20.

Shaft means 72 is provided to strengthen the control member 58 and also to provide a means for properly angularly locating the control member. Such locating is done by way of a knurled portion 74 on the shaft means. It can be seen in FIG. 2 that shaft means 72 extends out of the housing 68 and has an actuator means which includes lever 78 coupled thereto, the lever 78 further including stop means which includes a cam portion 78 adapted to engage tangs 70' of plate 70. The lever 78 may be coupled to the shaft 72 by suitable means such as by stacking or resistance welding, for example. It can be seen that by angular movement of the lever 78, shaft means 72 will displace control member 58.

The arrangement of the switching means 12, 14, 16 and 18 in conjunction with the control member 58 and the lever 78 can be seen in connection with FIGS. 4, 6 and 7. The switch means 12, 14, 16 and 18 are all substantially similar in structure, therefore, only one unit will be described. The switch means includes a rotor 80, an actuator 82, a toggle spring 84 and movable electrical contact ring 86. Displacement of contact ring 86 opens and closes electrical circuits of the switch means through engagement ofthe contact ring with the previously described stationary contacts. Contact ring 86 is carried by boss 102 extending from rotor 80, engagement between the contact ring and the boss being through rib 104. As shown in FIG. 4, rotor 80 is pivotally restrained and carried by a pivot post 88 carried by actuator 82. The pivot post 88 is rotatably journaled in base plate 20. A similar pivot post 90 extends from the opposed side of actuator 82. Pivot post 90 is receivably carried in an aperture 92 in cover plate 68. It can be seen in FIG. 4 that actuator 82, having pivot posts 90 and 88, is actuated between base plate 20 and cover plate 68 independent of rotor 80. Actuator 82 controls the rotor 80 by way of the toggle spring 84-. The toggle spring 84 is coupled to actuator 82 by way of one of the free ends of the spring 84 being connected to the actuator arm 94 of actuator 82 and to the rotor 80 by way of the other free end being coupled to boss 96 on the rotor. Actuator 82 also includes a receiving means such as recess 98. Recess 98 is designed to receive lug 100 which is located on the periphery of the control member 58. Recess 98 is positioned to face and receive the cam lobe 100 as the cam lobe is rotated past the actuator 82. This occurs both in the on and off switch positions as shown in FIG. 6. As cam lobe 100 rotates past the actuator 82, the actuator is pivoted from one position as indicated by the position of switch 12 to a second position as indicated by switch 18 until the actuator 82 stops against the sidewall of the cover plate 68.

In operation, it can be seen with reference to FIG. 1, that as the switches 12, 14, 16 and 18 are sequentially operated, current will flow through their respective resistors to supply the proper amount of voltage to the motor. As more resistors are electrically connected to the battery or the power supply, the ground lead absorbs the heat created by the resistors to therefore help dissipate the heat at a rapid rate. The operation of the switches themselves can be seen in FIGS. 2-7.

Rotation of control lever 78 to one of the four positions as indicated by the dotted lines in FIGS. 6 and 7 causes rotation of shaft 72 which is fixedly coupled to and rotatably moves control member 58. As control member 58 is rotated through different positions, cam lobes 100 will trip or actuate the switches 12, 14, 16 and 18. It should be noted that the geometrical location of the cam lobes 100 and the switching means is such that as a cam lobe 100 leaves recess 98 of one switch means, the next succeeding cam lobe starts to move actuator 82 of the next switch means. Thus there will be a constant force on the output shaft and lever so as to provide for smooth switching. As cam lobes 100 are engaged in recess 98 and start to move actuator 82 away from its at rest" position, actuator arm 94 will start to move in the same direction as that of cam lobe 100. As actuator arm 94 moves toward a line drawn between the center of pivot post 90 and the center of boss 96 on the rotor 80 (switch 12, FIG. 6) it will compress spring 84 and move the two free ends of the spring towards each other. This causes a buildup ofa compressive force in the spring until it reaches a maximum compression force determined by the size of wire and the length of the arms of the spring. As actuator arm 94 moves through and past the referenced line, the force built up in the spring will be released in that the free end of the spring which is secured to boss 96 will move the boss in the direction opposite to the movement of actuator arm 94 so as to reposition the contact ring 86 in abutment with its cooperating stationary terminal. Referring to switch 14, as rotor pivots from one position to the other, it in turn moves or carries contact ring 86 so as to engage the contact ring against a pair of stationary contacts 24 and 25. At this point, an electrical circuit has been completed from stationary terminal 24 through stationary contact 24, movable ring contact 86, stationary ground contact terminal 25 and ground terminal 30. At this point, there is provided an on" condition for the specific switch 14. As shown in FIG. 7, switches 16 and 18 are also closed or in the on" position, with switch 12 being open. As the control member 58 is moved in the opposite direction, the entire sequence of switch means 14 is reversed in that arm 94 moves through the center line drawn between boss 96 and pivot post so as to bias boss 96 by way oftoggle spring 84 in the opposite direction of the movement of the actuator arm so as to disengage contact ring 86 away from sta' tionary contacts 24 and 25 so as to open the circuits in switch means 141. Contact ring 86, at this point, will be engaged with lug 52. As previously mentioned, the control member can be rotated so that one or more switches can be open or closed at the same time. This is accomplished in a stepping fashion in that switch 12 is opened, followed by switches 14, 16 and 18. The switches are closed in a reverse cycle, that is, switch 18 is closed, then switches 16, 14 and 12.

Referring now to FIGS. 8 and 9 there is shown another embodiment of the invention. Control means 210 includes switching means 212, 214, 216, 218, the control means through the switching means being connected to a load such as motor 204 and a suitable power supply such as a battery 205. Whereas the embodiment exemplified by FIGS. l8 result in a programmed sequence which provides cumulative, or progressive increased resistance sequencing, the present embodiment, through the electrical connections, and the structural elements of the control means 210 provides a different sequencing. Thus the present invention is adaptable to a wide variety of programmed sequences. As shown, switching means 212 is connected to load 204 through resistor 206, switching means 214 is connected to the load through resistor 207, while switching means 216 and 218 are connected to the load through resistor 208.

In the present embodiment, the control means 210 includes an actuator means 220. Actuator means 220 includes lever 222 coupled to thumbwheel T. Thumbwheel T protrudes from a suitable panel P. Control means 210 is thus operated by rotating the thumbwheel as indicated by the arrows. Control means 210 is substantially similar to the control means of FIGS. 2-7. As shown, control means 210 includes stationary contacts 224, 224, 226, 226, 228, 228' and 230, 230 which cooperate with movable contact rings 242, 244, 246 and 248 to complete electrical circuits with stationary contacts 232, 234, 236, and 238. The first named stationary contacts are electrically connected to ground terminal 240, while the last named are connected to load 204. Control means 210 also includes control member 250 and actuator means 252 which make up elements of the individual switches. Although not shown for the purpose of clarity, there is also a rotor member similar to rotor member 80 of the embodiment of FIGS. 2-7.

The operation of the control means 210 is substantially the same as that of the control means 10 of FIGS. 2-7. But because of the electrical circuitry and the location of cam lobes 254 of control member 250, a different programmed sequence can be achieved.

Thus there is described a multiple control switch for regulating the speed ofa motor for applications such as blower motors for car heaters which, through its structural arrangement, includes many features. For example, the geometrical arrangement of the external terminals is such that the device lends itself to plug-in type terminal connectors (not shown). Except for the external terminals, the electrical units of the switch are completely enclosed in a dust-free type of environment. Perhaps more important, switching can readily be made according to a predetermined programmed sequence by merely changing the electrical circuitry and by changing the location ofthe cam lobes on the control members 58 and 250.

What is claimed is: I

l. A control means comprising:

a. a control member including a rotating hub and a flange carried by said hub, said flange including a plurality of cam lobes,

b. a plurality of switch means circumferentially disposed about said control member, said switch means including a spring-biased actuator means responsive to said cam lobes, a rotor rotationally responsive to said actuator means, said rotor including boss means, said boss means including means biasing electrical contact means into selective engagement with cooperating electrical contacts to open and close associated electrical circuitry,

c. actuating means coupled to said control member,

d. rotation of said control member selectively engaging said cam lobes with said switch means so as to cause actuation of said switch means in a programmed sequence.

2. A control means according to claim 1 wherein said electrical contact means is a ring surrounding said boss, and said means biasing said electrical contact means is a rib carried by said boss.

3. A control means comprising:

a. a base member and a cooperating cover plate disposed in spaced'parallel relationship,

b. a plurality, of electrical switch means circumferentially disposed about a centrally disposed control member and substantially between said base member and cooperating cover plate, said switch means including electrical terminal means, a switch actuator responsive to said centrally disposed control member and a rotor having a boss means and adapted to be moved in a plane parallel to said base member and said cover plate, said rotor having spring means for aiding in carrying loose ring electrical contacts placed around said boss means in and out of engagement with said terminals,

c. actuating means coupled to said centrally disposed control member, rotation of said centrally disposed member energizing said switch actuator.

4. A control means according to claim 3 wherein said spring means includes a toggle spring connected to said switch actuator and to said rotor.

5. A control means according to claim '3 wherein said centrally disposed member includes cam lobes selectively and individually engaging said switch actuator.

6. A control means according to claim 5 wherein said cam lobes are arranged with respect to said switch actuators such that as a cam lobe disengages a switch actuator, a next succeeding cam lobe engages a switch actuator of the next succeeding switch means. 

1. A control means comprising: a. a control member including a rotating hub and a flange carried by said hub, said flange including a plurality of cam lobes, b. a plurality of switch means circumferentially disposed about said control member, said switch means including a springbiased actuator means responsive to said cam lobes, a rotor rotationally responsive to said actuator means, said rotor including boss means, said boss means including means biasing electrical contact means into selective engagement with cooperating electrical contacts to open and close associated electrical circuitry, c. actuating means coupled to said control member, d. rotation of said control member selectively engaging said cam lobes with said switch means so as to cause actuation of said switch means in a programmed sequence.
 2. A control means according to claim 1 wherein said electrical contact means is a ring surrounding said boss, and said means biasing said electrical contact means is a rib carried by said boss.
 3. A control means comprising: a. a base member and a cooperating cover plate disposed in spaced parallel relationship, b. a plurality of electrical switch means circumferentially disposed about a centrally disposed control member and substantially between said base member and cooperating cover plate, said switch means including electrical terminal means, a switch actuator responsive to said centrally disposed control member and a rotor having a boss means and adapted to be moved in a plane parallel to said base member and said cover plate, said rotor having spring meAns for aiding in carrying loose ring electrical contacts placed around said boss means in and out of engagement with said terminals, c. actuating means coupled to said centrally disposed control member, rotation of said centrally disposed member energizing said switch actuator.
 4. A control means according to claim 3 wherein said spring means includes a toggle spring connected to said switch actuator and to said rotor.
 5. A control means according to claim 3 wherein said centrally disposed member includes cam lobes selectively and individually engaging said switch actuator.
 6. A control means according to claim 5 wherein said cam lobes are arranged with respect to said switch actuators such that as a cam lobe disengages a switch actuator, a next succeeding cam lobe engages a switch actuator of the next succeeding switch means. 